PR-1961 - Process Leak Management

Petroleum Development Oman
L.L.C.
Document Title: Process Leak

Management
Document ID PR-1961
Document Type Procedure
Security Unrestricted
Discipline Engineering and Operations
Owner UOP Functional Operations Manager
Issue Date November 2010
Revision 1.0
Revision: 1.0
Petroleum Development Oman LLC Effective: Nov-10
This page was intentionally left blank
Keywords: This document is the property of Petroleum Development Oman, LLC.

Neither the whole nor any part of this document may be disclosed to others or
reproduced, stored in a retrieval system, or transmitted in any form by any
means (electronic, mechanical, reprographic recording or otherwise) without
prior written consent of the owner.
Page 2 PR-1961 - Process Leak Management Printed 21/11/10

The controlled version of this CMF Document resides online in Livelink. Printed copies are UNCONTROLLED.
Revision: 1.0
i Document Authorisation
Authorised For Issue November 2010

Revision: 1.0
ii Revision History
The following is a brief summary of the 4 most recent revisions to this document. Details of all
revisions prior to these are held on file by the issuing department.
Revision Date Author Scope / Remarks

No.
Apr-11 Robin Norman UOP6 Added Section 1.7 ALARP

1.0 Nov-10 Robin Norman UOP6 1st Issue of Approved Procedure
Draft Oct-10 Robin Norman UOP6 New Document
iii Related Business Processes

Code Business Process (EPBM 4.0)
EP.71 Produce Hydrocarbons
EP.72 Maintain and Assure Facilities Integrity
iv Related Corporate Management Frame Work (CMF)

Documents
The related CMF Documents can be retrieved from the CMF Business Control Portal.
Refer to Appendix 3

Revision: 1.0
TABLE OF CONTENTS
1 Introduction........................................................................................................................... 6
1.1 Background..................................................................................................................... 6
1.2 Purpose........................................................................................................................... 6
1.3 Scope.............................................................................................................................. 6
1.4 Distribution / Target Audience.......................................................................................... 6
1.5 Changes to the Document............................................................................................... 6
1.6 Step-out Approval............................................................................................................ 7
1.7 ALARP............................................................................................................................. 7
2 Roles and Responsibilities.................................................................................................... 8
3 Process Leak Management................................................................................................... 9
3.1 Performance Standard.................................................................................................... 9
3.2 Definition for Weeps and Seeps......................................................................................9
3.3 Direct Response to Hydrocarbon Releases.....................................................................9
3.4 Delayed Repair of Weeps / Seeps................................................................................10
3.5 Process Leak Management Charts................................................................................11
3.5.1 Categorising the Leak..................................................................................11
3.5.2 Address the Leak.......................................................................................... 11
3.5.3 Repair the Leak............................................................................................ 12
3.5.4 Register of Temporary Leak Repairs............................................................13
3.6 Incident Recording and Reporting.................................................................................13
Appendix 1 - Monitoring Sheet for Weep / Seep Leaks (Delayed Repair).................................14
Appendix 2 - Abbreviations........................................................................................................ 15
Appendix 3 Reference Material...............................................................................................16
Appendix 4 - User Feedback Page............................................................................................ 17

Revision: 1.0
1 Introduction
1.1 Background
High level response procedures for Oil or Gas pipeline leaks is covered in PR-1066 -
Emergency Response Document Part III Contingency Plan Volume III - Production
Operations Sections 3.1.5 and 3.1.6. The details in these sections are for a major
emergency i.e. pipeline failure, where the immediate involvement of the Local
Emergency Base Controller (LEBC) would be notified and appropriate actions followed
as described in these sections.
Leaks within the facilities or in the immediate area of the facilities that would be
identified by operations as a normal part of their working routine are not effectively
covered in the Emergency Response Document and therefore a requirement exists to
address this situation and put in place contingency for dealing with such incidents.
1.2 Purpose
To provide concise instructions for indentifying, quantifying and addressing
hydrocarbon leaks within the facilities and associated flowlines.
NOTE: A sound awareness of the requirements of PR-1066 - Emergency Response
Document Part III Contingency Plan Volume III - Production Operations Sections 3.1.5
and 3.1.6 is required when using this procedure.
1.3 Scope
The scope of this procedure is;
To ensure a uniform approach is applied to dealing with hydrocarbon leaks and
seeps / weeps
To fulfil the PDO Corporate requirement for reporting leaks
To ensure the safety of personnel and assets at all times when investigating
leaks
1.4 Distribution / Target Audience

The procedure shall be used by all Operations and Contract staff when indentifying and
reporting leaks (including 2 phase) on facilities, equipment and flowlines.
1.5 Changes to the Document

Responsibility for the upkeep of the Document shall be with the Functional Operations
Team Leader UOP, the Owner. Changes to this document shall only be authorised and
approved by the Owner.
Users of the Document who identify inaccuracy or ambiguity can notify the Custodian
or his/her delegate and request changes be initiated. The Requests shall be forwarded
to the Custodian using the User Feedback Page provided in this Document.
The Document Owner and the Document Custodian should ensure review and re-
verification of this document every 3 years.

Revision: 1.0
1.6 Step-out Approval

Not applicable to this document.
1.7 ALARP
ALARP is the acronym for As Low As Reasonably Practicable which simplified means,
reducing the risk to a level at which the cost and effort (time and trouble) of further risk
reduction are grossly disproportionate to the risk reduction achieved. Full Compliance
to PDO Standards and Procedures is a key element in achieving ALARP.
For more details refer to ALARP Definition

Revision: 1.0
2 Roles and Responsibilities

Operations Manager Authorise repairs on major process leaks
TA2 Pipelines and Review repair method proposals for major and minor
Static Equipment process leaks and approve
Production Review repair proposals for weeps and seeps and
Coordinator approve
Oversee the Process Leak Management process at the
location of the leak
Production Supervisor Assist the Production Coordinator to review repair
proposals
Take control of leak management major and minor leaks
Control and monitor the activities of the investigation
teams during leak identification and location
Area Authority Assist the Production Supervisor in the control of leak
management major and minor leaks
Ensure site evacuation when required is carried out and
all personnel are mustered
Shutdown process or systems / equipment as required /
instructed
Ensure weeps and seeps are monitored and recorded
correctly

Revision: 1.0
3 Process Leak Management
3.1 Performance Standard

No accidental breach of the hydrocarbon envelope / loss of containment is
acceptable
Zero tolerance to hydrocarbon leaks
WARNING: All gas leaks have a flammable volume in proximity to the leak
source.
3.2 Definition for Weeps and Seeps

Hydrocarbon releases below a defined level are termed weeps or seeps. Such
releases are sufficiently small that immediate action may not be required.
Gas (and 2 phase)
<20% LEL measured at 0.1m from the leak source
OR
<0.1 litre per second (0.0001m 3/sec)
Liquid
<4 drops per minute
OR
<1 litre per 24 hour period
3.3 Direct Response to Hydrocarbon Releases

IMPORTANT
Personal safety is paramount at all times in the event of hydrocarbon releases
If there is any doubt about the atmosphere, work parties should withdraw
immediately from the affected area. This action shall be immediate if a
gas detector has gone into alarm
1. In the event of an alarm on portable monitors or fixed detection
equipment, personnel shall immediately evacuate the area of a
suspected leak and initiate a process shutdown if required. The
detected or suspected leak must be immediately reported to the
Station Control Room or the Central Control Room, the Production
Supervisor and the Production Coordinator.
2. Risk assessment shall be carried out by the production Supervisor and
Area Authority / Senior Operator to determine the safest method of
ongoing response;
a. Isolate equipment in affected area (if possible) or;
b. Obtain suitable safety equipment and investigate the source of
the leak
The risk assessment shall consider the type of leak, accumulation
possibilities (gas) especially in enclosed modules; the availability of
escape routes; wind strength and direction
NOTE: If the leak is gas and it contains H 2S urgent action shall be
taken to reduce the potential risks (where detection indicates the
release is greater than the allowed weep / weep level and the wind
Revision: 1.0
strength and direction would direct the cloud to populated areas.

WARNING: Personnel shall not investigate any gas leak, which has
initiated a process or station Shutdown, until the Production
Coordinator has given authorisation that the area is safe to enter.
A minimum of two persons shall investigate, appropriate PPE and safety
equipment i.e. SCBA, masks, face visors etc, shall be worn as necessary. One
person must be an authorised gas tester and carry a portable flammable gas
detector to detect the leak. This shall be in compliance with PR-1154 - Gas
Testing Procedure. The investigation team will remain in close proximity of each
other. The personal monitors shall ensure that each persons atmosphere is
monitored as breathable. This will help identifying borders of Hazardous Zone.
If at any time the monitors alarm, either because the breathable
atmosphere reaches 10% LEL, or through detection from the leak, then
the area shall be evacuated and the location recorded.
Once the leak is detected; surrounding area should be barricaded and marked
with adequate warning signs. Considering the wind direction gas detection shall
be established outside the barricaded area to insure limitation of exposure.
NOTE: When investigating a suspected hydrocarbon leak, radio
contact shall be maintained with the Station Control Room or
Production Supervisor / Coordinator overseeing the operation.
The investigation team shall ensure that they are safe at all times
whilst investigating the source of the leak and that they have
identified a direct escape route in the event that the situation
deteriorates. If any portable gas detector fails (or cannot be trusted),
the team will evacuate to a safe area and replace it.
3. If the source of the leak cannot be located or conditions surrounding
the leak get worse then the investigation team shall be recalled and
the situation re-assessed. This may require handing the incident over
to the LEBC as detailed in PR-1066 - Emergency Response Document Part
III Contingency Plan, Volume III Production Operations
3.4 Delayed Repair of Weeps / Seeps

Continued operation of a system or item of equipment shall not be permitted unless;
A local Risk Assessment has been completed and approved;
The leak rate / volume meets the criteria stated in Section 3.2 of this
procedure;
Any gas or vapour emissions cannot accumulate;
A repair plan has been prepared and SAP work orders entered;
The leak has a low potential of getting bigger;
All potential ignition sources within the area are identified and isolated;
Hot work activities are stopped within the potential area of the leak;
Regular monitoring has been arranged and barriers erected to stop or contain
access, and;
The leak is recorded and the record readily available to all operations
personnel on-site. The record shall show mitigating measures / deviation in
force (where applicable)

Revision: 1.0
Repair of hydrocarbon leaks should only take place on a de-pressurised system, except
in circumstances where the equipment has been designed specifically for online repair
(for example some valve stem packing systems.)

Revision: 1.0
3.5 Process Leak Management Charts
Categorising the Leak
Leak Medium Major leak Minor leak Weep / Seep leak
Flammable > 1m3 < 1 m3 <20% LEL measured at

Gas OR OR 0.1m from the leak source
>0.1 m3/s for more than 5 0.1 m3/s for < 2 minutes OR
minutes <0.1 litre per second
(0.0001m3/sec)
Hydrogen 100ppm H2S measured at 5ppm and <100ppm H2S Rotten eggs smell or <5ppm
Sulphide 1m from leak (or further measured at 1m from leak H2S measured at 1m from
away) (or further away) leak
Crude oil > 60ltrs < 60ltrs <4 drops per minute
(excluding OR OR OR
water cut) >0.2ltrs/s for > 5 minutes 0.2ltrs/s for < 5 minutes <1 litre per 24 hour period
Water Injection > 60ltrs < 60ltrs <4 drops per minute
OR OR OR
>0.2ltrs/s for > 5 minutes 0.2ltrs/s for < 5 minutes <1 litre per 24 hour period
NOTES:
1.) A leak is ANY escape of fluid or gas from a process system
2.) Water injection systems include DWD, SWD and pressurised water injection
Address the Leak
Location of Major leak Minor leak Weep / Seep leak

Leak
Pipeline Off- Evacuate affected Evacuate affected Shut in system
and On-Plot area (personnel, area (personnel, Report in FIM
ignition sources) ignition sources) and Repair before start up
Initiate ER if required assess if ER is
(PR-1066) required
Shut in system Shut in system
Report in FIM (tick Report in FIM
API-reportable) Investigation (PR-
Investigation (PR- 1418)
1418) Repair before start
DTL to sign Statement up
of Fitness before start
up
Flowline Off- Evacuate affected Evacuate affected Continue operating the
Plot area (personnel, area (personnel, flowline
NOTE: if the ignition sources) ignition sources) Record in leak log
leak is near to Initiate ER if required Shut in system Raise SAP notification
an ignition (PR-1066) Report in FIM for repair
source (e.g. Shut in system Repair before start Deviation in FSR until
OHLs), road, Report in FIM (tick up repaired (high risk sour
wadi or building, API-reportable) and gas flowlines only)
then treat as a Investigation (PR-
Pipeline. 1418)
Repair before start
up

Revision: 1.0

Leak
Process Evacuate affected Evacuate affected Continue operating the
Equipment On- area (personnel, area (personnel, system
Plot ignition sources) ignition sources) & Record in leak log
Initiate ER if required assess if ER is Notification in SAP for
(PR-1066) required repair
Shut in system Shut in system Deviation in FSR until
Report in FIM (tick Report in FIM repaired
API-reportable) Repair before start
Investigation (PR- up
1418)
DTL sign Statement
of Fitness before
start up
NOTES:
Colour coding indicates an initial potential risk level using RAM
Massive leaks (e.g. pipeline/vessel/tank ruptures, very large flammable or toxic gas
clouds, etc.) are not covered in this procedure but should be referenced in PR-1066 -
Emergency Response Document Part III Contingency Plan Volume III - Production
Operations and should be rated as red potential risk on the RAM
Repair the Leak

Leak
Pipeline Off- Pipelines TA-2 to approve Pipelines TA-2 to approve Approved by Prod./Maint.
and On-Plot Coordinator
Actions and repair shall Clamping
Pipelines TA-2 to approve
be evaluated case by
Partial replacement wrapping / clamping
case and authorised
after approval by the
Composite wrapping Tightening of flanges
Operations Manager
using FCP process.
Clamping
Partial replacement
Composite wrapping
Flowline Off- Static Mech. TA-2 to approve Static Mech. TA-2 to Approved by Prod./Maint.
Plot approve Coordinator
Clamping
Clamping Pipelines TA-2 to approve
Partial replacement wrapping / clamping
Partial replacement
Clamping
Process Static Mech. TA-2 to approve Static Mech. TA-2 to Approved by Prod./Maint.
Equipment On- approve Coordinator
Plot Actions and repair shall
be evaluated case by Clamping Pipelines TA-2 to approve
case and authorised wrapping / clamping
after approval by the Partial replacement
Operations Manager. Tightening of flanges
Composite wrapping
Clamping
Partial replacement
Composite wrapping
NOTE: ALL leaks should be actioned according to this procedure

Revision: 1.0
Register of Temporary Leak Repairs

Each Asset shall be required to maintain an active register of process leaks and the
temporary repairs carried out.
The register shall identify the method used to make the repair and the date by which a
permanent repair effected.
Risk Assessments shall be undertaken to mitigate risks to ALARP.
Hazardous (liquid and / or gas) leaks and leaks that affect the performance of SCEs
shall be entered on the FSR (flagged).
Ownership shall be the responsibility of the Production Supervisor or a nominee.
Leaks shall be allocated a unique repair ID. Number.
The register shall contain as a minimum the information detailed on the example
below.
3.6 Incident Recording and Reporting

All hazardous leaks should be recorded in the Fountain Incident Management (FIM)
system. Leaks recorded in FIM will be investigated in accordance with the incident
reporting and follow-up requirements. The following shall be recorded as a minimum;
The release flow-rate and quantity (volume) where possible;
Leak levels shall be classified as Major, Minor;
All leaks that can have an environmental impact shall be recorded in FIM.
NOTE: Weeps / seeps which do not have an environmental impact i.e. water, no-toxic
fluids etc, shall be recorded in the Station Leak Register and Daily Report.

Revision: 1.0
Appendix 1 - Monitoring Sheet for Weep / Seep Leaks (Delayed

Repair)
Link to Master Form

Revision: 1.0
Appendix 2 - Abbreviations
DWD Deep Water Disposal

ER Emergency Response
FIM Fountain Investigation Management system
FSR Field Safety Report
LEBC Local Emergency Base Controller
LEL Lower Explosive Limit
SWD Shallow Water Disposal
TA Technical Authority

Revision: 1.0
Appendix 3 Reference Material
PDO Code of Practice

CP-114 - Maintenance & Integrity Management Code of Practice
CP-115 - Operate Surface Product Flow Assets - CoP
PDO Specifications
SP-2020 - Flange Connections Bolt Torquing and Tensioning
PDO Procedures
PR-1066 - Emergency Response document Part III Contingency Plan, Volume III
Production Operations
PR-1146 Flowline Cold Cutting
PR-1154 Gas Testing Procedure
PR-1418 - Incident Notification, Reporting and Follow-up Procedure Part 1
PDO Guidelines
GU-379 - Pipeline Emergency Repair Manual

Revision: 1.0
Appendix 4 - User Feedback Page
PR-1961 Process Leak Management User Feedback Page
Any user who identifies an inaccuracy, error or ambiguity is requested to notify

the custodian so that appropriate action can be taken. The user is requested
to return this page fully completed, indicating precisely the amendment(s)
recommended.
Name:
Ref ID Date:
Page Ref: Brief Description of Change Required and Reasons
To: UOP7
Custodian of Document Date:


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Petroleum Development Oman

Document Title: Process Leak

Document Type Procedure

Discipline Engineering and Operations

Owner UOP Functional Operations Manager

Issue Date November 2010

This page was intentionally left blank

Keywords: This document is the property of Petroleum Development Oman, LLC.

Page 2 PR-1961 - Process Leak Management Printed 21/11/10

Page 3 PR-1961 - Process Leak Management Printed 21/11/10

Revision Date Author Scope / Remarks

Apr-11 Robin Norman UOP6 Added Section 1.7 ALARP

iii Related Business Processes

iv Related Corporate Management Frame Work (CMF)

Page 4 PR-1961 - Process Leak Management Printed 21/11/10

Page 5 PR-1961 - Process Leak Management Printed 21/11/10

1.4 Distribution / Target Audience

1.5 Changes to the Document

Page 6 PR-1961 - Process Leak Management Printed 21/11/10

1.6 Step-out Approval

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2 Roles and Responsibilities

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3 Process Leak Management

3.1 Performance Standard

3.2 Definition for Weeps and Seeps

3.3 Direct Response to Hydrocarbon Releases

strength and direction would direct the cloud to populated areas.

3.4 Delayed Repair of Weeps / Seeps

Page 10 PR-1961 - Process Leak Management Printed 21/11/10

Page 11 PR-1961 - Process Leak Management Printed 21/11/10

3.5 Process Leak Management Charts

Categorising the Leak

Leak Medium Major leak Minor leak Weep / Seep leak

Flammable > 1m3 < 1 m3 <20% LEL measured at

Address the Leak

Location of Major leak Minor leak Weep / Seep leak

Page 12 PR-1961 - Process Leak Management Printed 21/11/10

Location of Major leak Minor leak Weep / Seep leak

Repair the Leak

NOTE: ALL leaks should be actioned according to this procedure

Page 13 PR-1961 - Process Leak Management Printed 21/11/10

Register of Temporary Leak Repairs

3.6 Incident Recording and Reporting

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Appendix 1 - Monitoring Sheet for Weep / Seep Leaks (Delayed

Link to Master Form

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DWD Deep Water Disposal

Page 16 PR-1961 - Process Leak Management Printed 21/11/10

Appendix 3 Reference Material

PDO Code of Practice

Page 17 PR-1961 - Process Leak Management Printed 21/11/10

Appendix 4 - User Feedback Page

PR-1961 Process Leak Management User Feedback Page

Any user who identifies an inaccuracy, error or ambiguity is requested to notify

Page Ref: Brief Description of Change Required and Reasons

Page 18 PR-1961 - Process Leak Management Printed 21/11/10

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